Honda NU50 - 5. Engine Removal and Installation

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ENGINE

REMOVAL/INSTALLATION

5-0

~HONDA

~NUSO.NUSOM

Date of

Issue:

Nov.,

198\

lTD.

Main Page

Contents3
General Information4
General Safety4
Service Rules4
Model Identification5
Specifications6
Tools8
Torque Values9
Standard to Roue Values9
Cable & Wire Harness Routing10
Lubrication System14
Lubrication15
Service Information15
Lubrication Troubleshooting16
Overheating16
Seized Piston16
Oil Not Flowing out of Tank16
Final Reduction Oil17
Oil Tank17
Oil Level Check17
Oil Strainer Cleaning19
Oil Pump19
Oil Pump Bleeding21
Oil Inlet Line21
Oil Outlet Line21
Lubrication Points22
Maintenance23
Maintenance Schedule24
Fuel Lines25
Fuel Strainer25
Air Cleaner26
By Starter Element26
Spark Plug27
Throttle Operation27
Thaotile Cable Adjustment27
Oil Pump Control Cable Adjustment28
Idle Speed Adjustment28
Ignition Timing29
Compression Test29
Battery30
Brakes30
Brake Adjustment30
Brake Shoe Inspection31
Suspension31
Steering Head Bearings32
Headlight Aim32
Wheels/Tires32
Nuts, Bolts, Fasteners33
Fuel System35
Throttle Valve Disassembly36
Carburetor Removal37
Float/Float Valve/Jets Disassembly37
Float/Float Valve Inspection38
Jets/Float Valve/Float Assembly39
Float Level Inspection39
Carburetor Installation40
Throttle Valve Installation40
Reed Valve Removal42
Reed Valve Inspection42
Reed Valve Installation42
Fuel Filter and Tank43
Fuel Strainer Cleaning43
Fuel Tank Removal44
Fuel Tank Installation44
Engine Removal/Installation46
Engine Removal47
Engine Installation48
Cylinder Head/Cylinder/Piston50
Cylinder Head Removal51
Cylinder Head Inspection51
Cylinder Head Decarbonizing52
Piston Removal53
Piston Ring/Expander Removal53
Cylinder/Piston Inspection53
Piston Ring Inspection55
Connecting Rod Inspection55
Piston/Cylinder Installation55
Cylinder Head Installation57
Alternator60
Alternator Removal61
Alternator Installation63
Drive Pulley/Kick Starter/Clutch/Driven Pulley66
Drive Pulley68
Left Crankcase Cover Removal68
Kick Spindle Bearing Inspection68
Bearing Replacement69
Drive Belt Removal69
Drive Belt Inpection69
Movable Drive Face Removal/Disassembly70
Movable Drive Face Disassembly70
Movable Drive Face Inspection71
Movable Drive Face Assembly72
Movable Drive Face Installation73
Left Crankcase Cover Installation74
Kick Starter75
Kick Starter Removal76
Kick Starter Disassembly77
Kick Starter Inspection77
Kick Starter Assembly79
Kick Starter Installation80
Clutch/Driven Pulley81
Clutch Removal82
Drive Face Disassembly83
Clutch/Driven Face Inspection85
Driven Face Assembly87
Driven Pulley Assembly87
Clutch/Driven Pulley Installation88
Final Reduction89
Final Reduction Disassembly91
Final Reduction Inspection93
Final Reduction Installation93
Transmission Cover Assembly94
Crankcase/Crankshaft97
Crankcase Separation98
Crankshaft Removal99
Crankshaft Inspection99
Crankcase Assembly101
Steering/Front Wheel/Front Brake/Front Fork103
Speedometer105
Headlight106
Headlight Case Removal/Installation107
Ignition Switch Replacement108
Indicator Lamp Replacement108
Handlebar Removal109
Handlebar Installation110
Front Wheel Removal112
Front Wheel Axle Inspection112
Wheel Bearing Inspection112
Wheel Rim Inspection113
Front Wheel Disassembly113
Front Brake Drum Inspection113
Front Wheel Assembly114
Front Wheel Installation114
Front Brake115
Brake Lining Inspection115
Brake Panel Disassembly116
Brake Cam Assembly116
Front Fork Removal117
Front Fork Disassembly/Inspection118
Front Spring Inspection119
Front Fork Assembly/Installation119
Steering Stem120
Ball Race Disassembly/Assembly120
Steering Stem Installation121
Rear Wheel/Rear Brake/Rear Suspension123
Rear Wheel Removal124
Rear Wheel Rim Runout Inspection124
Rear Brake Drum Inspection125
Rear Wheel Installation125
Rear Brake126
Rear Brake Lining Thickness Inspection126
Rear Brake Assembly127
Shock Absorber Removal128
Free Length130
Electrical Equipment132
Specific Gravity Test134
Battery Charging135
Charging System136
Performance Test137
Alternator Inspection137
Technical Data137
Silicon Rectifier Inspection137
Ignition System138
Ignition Circuit138
Ignition Coil139
C.D.I. Unit140
Regulator/Rectifier142
Resistor142
Starting System143
Starter Relay Inspection143
Starter Motor Removal143
Starter Motor Disassembly144
Brush Inspection144
Commutator Inspection144
Starter Motor Assembly145
Starter Motor Installation145
Switches/Horn146
Combination Horn146
Turn Signal Switch146
Headlight Dimmer Switch146
Front/Rear Stop Light Switch147
Engine Stop Switch147
Starter Switch147
Oil Level Sensor148
Indicator Switch Inspection148
Technical Features149
C.D.I.149
Automatic Choke151
Bystarter Chamber151
Control Box151
V-Matic Drive153
Oil Level Indicator156
Blown Bulb Detection156
Construction156
Oil Level Detection157
Troubleshooting158
Engine will Not Start or Is Hard to Start158
Engine Lacks Power159
Poor Performance at Idle and Low Speed159
Poor High Speed Performance160
Steers to One Side or Does Not Track Straight160
Starter Motor Does Not Rotate161
Motor Rotates Sluggishly or Fails to Crank Engine161
Starter Won't Stop Rotating161
Indicator Lamp Does Not Light When Ignition Switch Is Turned on162
Indicator Lamp Remains on with Sufficient Oil in Oil Tank162
Wiring Diagram163
Required Special Tools166
Engine Tools166
Chassis Tools167
Convenience Tools167
Crankcase Disassembly Tool Modification167
Motorcycles in Dealer Inventory170
Parts Information170
Air Cleaner Bracket171
Description of Defect171
Owner Notification171
Bracket Replacement Procedure172

Honda NU50 - 5. Engine Removal and Installation

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